Building construction components
A stud that may be used as a header, as a sill, as a jamb stud, in a support post assembly and as a floor girder. In one embodiment, the stud has a substantially planar web, a first flange and a second flange that each protrude from the web. A first leg protrudes from the first flange such that the first leg is substantially parallel to the substantially planar header web. Likewise, a second leg protrudes from the second flange such that it is substantially parallel to the substantially planar header web. A first return protrudes from the first leg and a second return protrudes from the second leg. Stiffener ribs may be provided in at least one of the web, the first and second flanges and/or the first and second legs.
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This application is a divisional patent application of U.S. patent application Ser. No. 10/981,868, filed Nov. 5, 2004 now abandoned, entitled “BUILDING CONSTRUCTION COMPONENTS”, the disclosure of which is herein incorporated in its entirety.
BACKGROUND OF THE INVENTION1. Field of the Invention
The invention relates to building construction components and, more particularly, to building construction components fabricated from metal such as headers, sills, trusses, girders and support posts.
2. Description of the Invention Background
Traditionally, the material of choice for new residential and commercial building framing construction has been wood. However, over the years, the rising costs of lumber and labor required to install wood framing components have placed the dream of owning a newly constructed home out of the economic reach of many families. Likewise, such increasing costs have contributed to the slowing of the development and advancement of urban renewal plans in many cities. Other problems such as the susceptibility to fire and insect damage, rotting, etc. are commonly associated with wood building products.
In view of the foregoing problems and shortcomings of wood construction, steel is rapidly gaining acceptance among homebuilders and homeowners alike due to its cost effectiveness, dimensional stability, noncombustibility, insect resistance, durability, high strength-to-weight ratio and recycleability. These advantages have long been recognized by the commercial construction industry wherein steel has been the material of choice for several decades.
Regardless of whether a building comprises a multistory commercial structure or a single story residence, C-shaped metal studs and tracks are commonly used in their construction.
In most construction applications, walls are constructed by attaching a series of C-shaped studs between a top track and a bottom track. The bottom track is usually attached to the floor structure by screws or other fasteners and the top track is usually attached to the ceiling joists. The ends of the studs are inserted into the top and bottom tracks and are attached thereto by screws, welds, etc. After the wall frame is constructed, then the desired wallboard material is attached to the flanges of the studs and tracks utilizing screws or other fasteners to complete the wall assembly.
In those walls that require door and/or window openings to be framed therein, a header is constructed to transfer loads occurring above the opening to the vertically extending studs adjacent the opening. The studs that define the vertical boundaries of the opening are often referred to as the “jamb” studs.
Likewise, the jamb studs 50 are each commonly formed by attaching a C-shaped stud 52 to another piece of track 60 such that the flanges 56 of the stud 52 are received between the flanges 64 of the track 60 and then attaching the web 72 of another stud 70 to the web 64 of the track 60. These components are also commonly coupled together with screws 49 which can lead to drywall finishing problems. In the alternative, they may be welded together to form the jamb stud 50. Such assembly approach requires additional skilled labor. These combinations of components have been found to provide the jamb stud with a sufficient amount of strength to receive the loads from the header without failing or buckling.
To complete the header assembly, the header 30 is then attached to each jamb stud 50 by corresponding L-shaped clips 80. The clips 80 are welded or screwed to each jamb stud 50. In addition, sections of studs 82 are attached between the track 60 and the section of upper track (not shown) to which the upper ends of the jamb studs 50 are attached. Such stud segments 82 are often referred to in the industry as “cripple studs” and further transfer loads from the upper structures to the header.
Conventional C-shaped studs and tracks are also used to form support posts for supporting loads from the structures located above the posts.
Floors are also constructed utilizing components that are somewhat identical to C-shaped studs and tracks utilized to form the wall frames for the structure. However, the tracks and C-shaped members used to form the floor structure can be larger than those like-shaped components used to form wall structures. The floor of a structure is commonly formed from a series of C-shaped members that span the distance between support structures or support walls. These C-shaped members are commonly referred to as floor joists. The ends of the joists are coupled to tracks referred to as joist rims that are either supported on a wall or other structure by one of their flanges or have their webs attached to the wall or structure. The joists are commonly attached to the joist rims by conventional L-shaped clips or by tabs that are integrally formed in the web of the joist rim.
In those instances wherein the span is too long or loading conditions require it, beams known as girders are employed. The girders serve as points of attachments for the ends of adjacent floor joists as shown in
Thus, as can be appreciated from the forgoing discussion, a variety of different components utilized in constructing residential and commercial buildings from steel are fabricated from conventional C-shaped studs and tracks. While the use of such components affords a host of advantages over the use of wood beams and the like, the added labor and materials required to fabricate such components undesirably lead to increased construction costs.
SUMMARYIn accordance with one embodiment of the present invention, there is provided a header assembly that includes a first vertically extending jamb stud and a second vertically extending jamb stud supported in spaced apart relationship. A first connector is attached to the first vertically extending jamb stud. The first connector has a pair of spaced legs that define a first header-receiving area therebetween. A second connector is attached to the second vertically extending jamb stud and has a pair of spaced legs that define a second header-receiving area therebetween. The header assembly also comprises a single-piece, integral header that has a first end that is received in the first header-receiving area of the first connector and a second end that is received in the second header-receiving area of the second connector. The header also spans between the first and second vertically extending jamb studs to define an opening therebetween. In one embodiment, the header comprises a substantially planar header web that has a first header flange and a second header flange protruding therefrom. A first header leg protrudes from the first header flange and is substantially parallel to the substantially planar header web. A second header leg protrudes from the second header flange and is substantially parallel to the substantially planar header web and is substantially coplanar with the first header leg to define support surfaces spanning between the first and second upwardly extending jamb studs. A first header return is formed on an end of the first header leg and a second header return is formed on an end of the second header leg.
Another embodiment of the present invention comprises a wall structure that includes a bottom track, a top track and a plurality of vertically extending studs that extend between the top and bottom tracks and are attached thereto. A first jamb stud extends between the top and bottom tracks and is attached thereto. A second jamb stud also extends between the top and bottom tracks and is attached thereto such that it is spaced from the first jamb stud. A first connector that has a pair of spaced legs that define a first header-receiving area therebetween is attached to the first jamb stud. A second connector that has a pair of spaced legs that define a second header-receiving area therebetween is attached to the second jamb stud. The wall structure of this embodiment further includes a single-piece, integral header that has a first end received in the first header-receiving area of the first connector and a second end that is received in the second header-receiving area of the second connector. The header also spans between the first and second vertically extending jamb studs to define an opening therebetween. In one embodiment, the header comprises a substantially planar header web, a first header flange that protrudes from the substantially planar header web and a second header flange that protrudes from the substantially planar header web. The second header flange is spaced from the upwardly extending first header flange. A first header leg protrudes from the first header flange and is substantially parallel to the substantially planar header web. A second header leg protrudes from the second header flange and is substantially parallel to the substantially planar header web and is substantially coplanar with the first header leg to define support surfaces spanning between the first and second jamb studs. A first header return is formed on an end of the first header leg and a second header return is formed on an end of the second header leg.
Another embodiment of the subject invention comprises a header assembly that includes a first vertically extending jamb stud and a second vertically extending jamb stud that is supported in spaced apart relationship with respect to the first vertically extending jamb stud. A first connector is attached to the first vertically extending jamb stud. The first connector has a raised first central portion with first return-receiving grooves therein. Likewise, a second connector is attached to the second vertically extending jamb stud. The second connector has a raised first central portion with second return-receiving grooves therein. The header assembly of this embodiment further comprises a single-piece, integral header that has a substantially planar header web, a first header flange that protrudes from the substantially planar header web and a second header flange that protrudes from the substantially planar header web and is spaced from the first header flange. A first header leg protrudes from the first header flange and is substantially parallel to the substantially planar header web. A second header leg protrudes from the second header flange and is substantially parallel to the substantially planar header web and is substantially coplanar with the first header leg to define support surfaces spanning between the first and second vertically extending jamb studs. The first header web and the first and second header flanges and legs defining a hollow area within the header. A first header return is formed on an end of the first header leg and a second header return is formed on an end of the second header leg. The header is supported between the first and second jamb studs such that the first raised central portion of the first connector is received in the hollow area within one end of the header such that the first and second header returns are received in the first return-receiving grooves in the first raised central portion. The second raised central portion of the second connector is received in the hollow area adjacent another end of the header such that the first and second returns are received in the second return-receiving grooves in the second raised central portion.
Yet another embodiment of the present invention comprises a wall structure that includes a bottom track, a top track and a plurality of vertically extending studs that extend between the top and bottom tracks and are attached thereto. A first jamb stud extends between the top and bottom tracks and is also attached thereto. Likewise, a second jamb stud extends between the top and bottom tracks and is attached thereto such that the second jamb stud spaced from the first jamb stud. A first connector having a raised first central portion with first return-receiving grooves therein is attached to the first jamb stud. A second connector having a second raised central portion with second return-receiving grooves therein is attached to the second jamb stud. The wall structure of this embodiment further includes a single-piece, integral header that has a substantially planar header web, a first header flange that protrudes from the substantially planar header web and a second header flange that protrudes from the substantially planar header web and is spaced from the first header flange. A first header leg protrudes from the first header flange and is substantially parallel to the substantially planar header web. A second header leg protrudes from the second header flange and is substantially parallel to the substantially planar header web and is substantially coplanar with the first header leg to define support surfaces spanning between the first and second vertically extending jamb studs. The first header web and the first and second header flanges and legs defining a hollow area within the header. A first header return is formed on an end of the first header leg and a second header return is formed on an end of the second header leg. The header is supported between the first and second jamb studs such that the first raised central portion of the first connector is received in the hollow area within one end of the header such that the first and second header returns are received in the first return-receiving grooves in the first raised central portion. The second raised central portion of the second connector is received in the hollow area adjacent another end of the header such that the first and second returns are received in the second return-receiving grooves in the second raised central portion.
Still another embodiment of the present invention comprises a truss assembly that includes a chord stud that has a chord web, a first chord flange that protrudes from the chord web and a second chord flange that protrudes from the chord web and is spaced from the first chord flange. A first chord leg protrudes from the first chord flange and is substantially parallel to the chord web. A second chord leg protrudes from the second chord flange and is substantially parallel to the chord web and is substantially coplanar with the first chord leg. A first chord return is formed on an end of the first chord leg and a second chord return is formed on an end of the second chord leg. A plurality of truss webs are attached to the chord stud.
Another embodiment of the present invention comprises a support post that includes a post stud that comprises a substantially planar post web, a first post flange that protrudes from the substantially planar post web and a second post flange that protrudes from the substantially planar post web and is spaced from the first post flange. A first post leg protrudes from the first post flange and is substantially parallel to the substantially planar post web. A second post leg protrudes from the second post flange and is substantially parallel to the substantially planar post web and substantially coplanar with the first post leg. A first post return is formed on an end of the first post leg and a second post return is formed on an end of the second post leg. First and second studs are fastened to the post stud.
Another embodiment of the present invention comprises a floor system that includes a floor girder which includes a substantially planar girder web, a first girder flange that protrudes from the substantially planar girder web and a second girder flange that protrudes from the substantially planar girder web and is spaced from the first girder flange. A first girder leg protrudes from the first girder flange and is substantially parallel to the substantially planar girder web. A second girder leg protrudes from the second girder flange and is substantially parallel to the substantially planar girder web and is substantially coplanar with the first girder leg. A first girder return is formed on an end of the first girder leg and a second girder return is formed on an end of the second girder leg. At least one first joist and at least one second joist are fastened to the girder.
Another embodiment of the present invention comprises a single-piece, integral header stud. In one embodiment, the header stud includes a substantially planar header web and first and second header flanges that protrude from the substantially planar header web. A first header leg protrudes from the first header flange and is substantially parallel to the substantially planar header web. A second header leg protrudes from the second header flange and is substantially parallel to the substantially planar header web and is substantially coplanar with the first header leg. A first header return is formed on an end of the first header leg and a second header return is on an end of the second header leg. At least one stiffener rib is formed in at least one of the planar header web, the first header flange, the second header flange, the first header leg and the second header leg.
Another embodiment of the present invention comprises a sill assembly that includes a first vertically extending jamb stud and a second vertically extending jamb stud that is supported in spaced apart relationship with respect to the first vertically extending jamb stud. A first C-shaped connector attached to the first vertically extending jamb stud and has a pair of spaced first flanges that define a first sill-receiving area therebetween. A second C-shaped connector is attached to the second vertically extending jamb stud and has a pair of spaced second flanges that define a second sill-receiving area therebetween. The sill assembly further includes a single-piece, integral sill stud that has a first end received in the first sill-receiving area of the first C-shaped connector and a second end received in the second sill-receiving area of the second C-shaped connector. The sill stud spans between the first and second vertically extending jamb studs and in one embodiment comprises substantially planar sill stud web and a first sill stud flange that protrudes from the substantially planar sill stud web and a second sill stud flange that protrudes from the substantially planar sill stud web and is spaced from the first sill stud flange. A first sill stud leg protrudes from the first sill stud flange and is substantially parallel to the substantially planar sill stud web. A second sill stud leg protrudes from the second sill stud flange and is substantially parallel to the substantially planar sill stud web and is further substantially coplanar with the first sill stud leg. A first sill stud return is formed on an end of the first sill stud leg and a second sill stud return is formed on an end of the second sill stud leg.
In the accompanying Figures, there are shown present embodiments of the invention wherein like reference numerals are employed to designate like parts and wherein:
Referring now to the drawings for the purposes of illustrating the present embodiments of the invention only and not for the purposes of limiting the same,
In this embodiment, the header assembly 219 is formed from a uniquely shaped header stud 220, one embodiment of which is depicted in
In one embodiment, the stud 220 is rollformed from steel sheet by utilizing conventional rollforming methods and equipment. For example, the stud 220 may be fabricated from 12, 14, 16, 18, 20, etc. gage steel or other metal or material. Although the size of the stud 220 and the material from which it is formed may vary depending upon the application and loading conditions, in one embodiment for example, the web 222 may be made in various widths of, for example, 3⅝ inches, 6 inches and eight inches (distance “A”). The first and second flanges (224, 226) may be fabricated with a variety of different heights ranging from, for example, 2 inches-3.5 inches (distance “B”). The widths of the first and second legs (228, 230) of a stud that has a web width of 3⅝ inches may be 1 1/16 inches (distance “C”). Thus in this embodiment, the distance between the ends of the first and second legs (228, 230) is 1½ inches (distance “D”). The widths of the first and second legs (228, 230) of a stud that has a web width of six inches would be, for example, 2¼ inches. The widths of the first and second legs (228, 230) of a stud that has a web width of eight inches would be, for example, 3¼ inches. In various embodiments, the length of each return portion (232, 234) may be ¾ inches (distance “E”). It will be appreciated, however, that other sizes of stud 220 could be used depending upon the specific application.
In the embodiment depicted in
As can be seen in
As shown in
As can also be seen in
In this embodiment, the sill stud 220″ is oriented with the flanges 224″ and 226″ extending toward the lower track 202 and is coupled to the jamb studs 220′ by connector clips 240 in the manner described above. Also in this embodiment, a sill track 260″ is supported on and attached to the first and second legs (228″, 230″) of the sill stud 220″. Sill track 260″ has a sill track web 262″ and a pair of upstanding sill track flanges 264″. The sill track web 262″ of the sill track 260″ is attached to the first and second sill track legs (228″, 230″) of the sill stud 220″ by fasteners 246″ which may comprise conventional sheet metal screws or the like. In addition, pieces of studs 270″, which may be conventional in nature, may be attached to the sill track 260″ and the lower track 202. Studs 270″ may each have a web 272″, pair of flanges 274″ and a return 276″ formed on the end of each flange 274″. The flanges 274″ of the studs 270″ are attached to the sill track flanges 264″ and the lower track flanges 208 by fasteners 246″ such as sheet metal screws or the like. Studs 270″ serve as the cripple studs for the sill 280.
Such header, jamb stud and sill arrangements of the present invention require less labor and material to assemble than the prior header configurations. It will also be appreciated, however, that the uniquely shaped studs 220, 220′, 220″ could be used in a variety of other applications and combinations. For example, the header studs 220 and the sill studs 220″ could be used to form headers and sills, respectively as described above in connection with conventional jamb stud arrangements. Likewise, the studs 220′ could be used to form jamb studs that are used in connection with conventional header and sill assemblies. Thus, it will be appreciated that the header studs 220 and/or sill studs 220″ do not have to be used in connection with jamb studs 220′ if use of other jambs stud arrangements is more preferable and visa-versa. It will be also appreciated that the studs (220, 220′, 220″) could be used in connection with wood studs and wood framing assemblies.
In another header assembly embodiment of the present invention, a connector clip 290 of the type illustrated in
In this embodiment, the post stud 410 is used in connection with two studs 430. The studs 430 each have a web 432 and two flanges 434. A lip 436 is formed on the end of each flange 434. The post 400 is formed by attaching the web 432 of one of the studs 430 to the post stud web 412 of the post stud 410 with fasteners 438 such as sheet metal screws or the like and the web 432 of the other stud 430 is attached to the first and second post stud legs (418, 420) of the post stud 410 by sheet metal screws 438 or the like. I have discovered that such arrangement provides an equivalent amount of structural support as prior post arrangements that employ three conventional studs and two pieces of conventional track. Thus, this embodiment of the present invention reduces the amount of material needed and also the amount of labor needed to assemble it when compared to prior post assemblies. It will be appreciated, however, that the post stud 410 may also be used in connection with one stud 430 or more than two studs 430 without departing from the spirit and scope of the present invention.
The unique and novel studs of the present invention may also be used as a floor girder 502 in a floor system 500. More particularly and with reference to
The floor joists 530 may have a joist web 532 and a first joist flange 534 and a second joist flange 536. A first joist lip 538 is formed on the end of the first joist flange 534 and a second joist lip 540 is formed on the end of the second joist flange 536. One series of joists 530 are attached to the first and second girder legs (518, 520) of the girder stud 510 by conventional L-shaped clips 550 and sheet metal screws 552 or the like. The joists 530 protruding from the other side of the girder stud 510 are attached to the girder web 512 of the girder stud 510 by L-shaped clips 550 and fasteners 552. Such improved arrangement eliminates the need to assemble the girder from a conventional stud and track and the labor associated with making such girder. It will be further appreciated that the girder of the present invention may find utility in non-floor applications without departing form the spirit and scope of the present invention.
In one embodiment, the stud 620 is rollformed from steel sheet by utilizing conventional rollforming methods and equipment. For example, the stud 620 may be fabricated from 12, 14, 16, 18, 20, etc. gage steel or other metal or material. In this embodiment, the stud 620 may further include a series of stiffener ribs. More particularly and with reference to
In yet another embodiment, one or more access holes 700 may be provided through the webs of studs 220, 220′, 220″, 620 disclosed herein. See
As can be appreciated from the foregoing description, the unique and novel stud configurations of the present invention may have a variety of advantages over prior component configurations. In particular, when used in window and door framing applications, the novel stud arrangements of the present invention eliminate the buildup activities associated with prior methods. The invention which is intended to be protected is not to be construed as limited to the particular embodiments disclosed. The embodiments are therefore to be regarded as illustrative rather than restrictive. Variations and changes may be made by others without departing from the spirit of the present invention. Accordingly, it is expressly intended that all such equivalents, variations and changes which fall within the spirit and scope of the present invention as defined in the claims be embraced thereby.
Claims
1. A header assembly comprising:
- a first vertically extending jamb stud;
- a second vertically extending jamb stud supported in spaced apart relationship with respect to said first vertically extending jamb stud;
- a first connector attached to said first vertically extending jamb stud, said first connector having a raised first central portion with first return-receiving grooves therein;
- a second connector attached to said second vertically extending jamb stud and having a raised second central portion with second return-receiving grooves therein; and
- a rollformed header comprising: a substantially planar header web; a first header flange protruding from said substantially planar header web; a second header flange protruding from said substantially planar header web and being spaced from said first header flange; a first header leg protruding from said first header flange and being substantially parallel to said substantially planar header web; a second header leg protruding from said second header flange and being substantially parallel to said substantially planar header web and substantially coplanar with said first header leg to define support surfaces spanning between said first and second vertically extending jamb studs, said first header web and said first and second header flanges and legs defining a hollow area within said header; a first header return on an end of said first header leg; and a second header return on an end of said second header leg and wherein said header being supported between said first and second jamb studs such that said first raised central portion of said first connector is received in said hollow area within one end of said header such that said first and second header returns are received in said first return-receiving grooves in said first raised central portion and wherein said second raised central portion of said second connector is received in said hollow area adjacent another end of said header such that said first and second returns are received in said second return-receiving grooves in said second raised central portion.
2. The header assembly of claim 1 further comprising an upper track supported on said first and second header legs.
3. The header assembly of claim 1 wherein said header is formed from cold formed metal.
4. The header assembly of claim 1 wherein at least one of said first and second jamb studs comprises:
- a substantially planar jamb stud web;
- a first jamb stud flange protruding from said substantially planar jamb stud web;
- a second jamb stud flange protruding from said substantially planar jamb stud web and being spaced from said first jam stud flange;
- a first jamb stud leg protruding from said first jamb stud flange and being substantially parallel to said substantially planar jamb stud web;
- a second jamb stud leg protruding from said second jamb stud flange and being substantially parallel to said substantially planar jamb stud web;
- a first jamb stud return on an end of said first jamb stud leg; and
- a second jamb stud return on an end of said second jamb stud leg.
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Type: Grant
Filed: Jun 15, 2007
Date of Patent: Jun 22, 2010
Patent Publication Number: 20080028702
Assignee: Dietrich Industries, Inc. (Columbus, OH)
Inventor: Larry Randall Daudet (Chesterton, IN)
Primary Examiner: Phi Dieu Tran A
Attorney: Fay Sharpe LLP
Application Number: 11/818,598
International Classification: E06B 3/92 (20060101); E06B 5/00 (20060101);